Prefabricated roofing panel composite

ABSTRACT

A prefabricated roofing panel composite includes a prefabricated cover board having a high-density polymer or predominantly polymer material core layer having a density between 6 lbs/ft 3  and 25 lbs/ft 3  and an insulation board that has a low-density polymer or predominantly polymer material foam core layer having a density less than or equal to about 2 lbs/ft 3 . The cover board may have a waterproofing membrane forming the top major surface of the cover board. The low-density foam core layer of the insulation board may be formed with the high-density core layer of the cover board being currently or subsequently formed over and bonded to a top major surface of the low-density foam core layer in the same operation or preformed insulation boards may be fed into a production line with the high-density core layer of the cover board being formed over and bonded to top major surfaces of the low-density foam core layers of the insulation boards.

FIELD OF ART

The present disclosure relates to a prefabricated roofing panelcomposite, which includes the high-density polymer or predominantlypolymer material cover board and a low-density polymer or predominantlypolymer material foam insulation board, and to a method of making theroofing panel composite.

BACKGROUND

Commercial and industrial buildings typically have roofs with low-sloperoof decks. The roofing systems for these roofs with low-slope roofdecks typically include one or more layers of a low-density roofinginsulation, a layer of roofing cover boards that overlie the low-densityroofing insulation layer(s), and a waterproofing membrane that overliesthe layer of cover boards. The layer(s) of low-density insulation, suchas a low-density polymer-based foam insulation, if not protected, can bepartially crushed or otherwise damaged from worker traffic over theinsulation, the placement of heaving objects on the insulation, theweather, and other causes commonly encountered in roofing construction.The layer of roofing cover boards that overlies the one or more layersof low-density insulation, protects the more fragile low densityinsulation from damage, acts as a fire barrier, provides a suitablesubstrate for the attachment of the overlying waterproofing membrane,and augments the insulating function of the low-density insulation. Theuppermost waterproofing membrane layer overlying the cover board layerprotects the underlying cover board and insulation layers from moistureand other adverse climatic conditions. Normally, these three components(the low-density insulation boards, the roofing cover boards, and thewaterproofing membrane) of the roofing system are separatelymanufactured and separately and successively applied to the low-sloperoof deck. While these roofing systems function very well, there hasremained a need to prefabricated roofing panel composites that combineat least an insulation board and a roofing cover board layer, and that,preferably, combine an insulation board, a roofing cover board layer anda waterproofing membrane. With the use of such prefabricated roofingpanel composites, roofing systems for low-slope roof decks can beimproved and/or the time, labor and costs associated with theinstallation of roofing systems on low-slope roof decks can be reduced.Provided is an improved prefabricated roofing panel cover board andinsulation board composite, and an improved prefabricated roofing panelcover board, insulation board, and waterproofing membrane composite.Also provided is a method for making the prefabricated roofing panelcomposites including roofing cover board that is highly productive,relatively economical, and efficient.

SUMMARY

The presently disclosed high-density polymer or predominantly polymermaterial cover board is or includes a high-density polymer orpredominantly polymer material core layer with a density between 6lbs/ft³ and 25 lbs/ft³. The density and thickness of the high-densitypolymer or predominantly polymer material core layer of the cover boardare selected to provide the cover board with the compressive strength toresist deformation so that the cover board protects low-densityinsulation layers overlaid by the cover board from damage and so thatthe cover board has surface characteristics that promote the bonding ofa top facer, e.g., waterproofing membrane, to the high-density corelayer of the cover board. The presently disclosed prefabricatedhigh-density polymer or predominantly polymer material cover board isrelatively lightweight and easily cut. This makes the prefabricatedroofing panel cover board and insulation board composite easier toinstall and increases the productivity of workers installing theprefabricated roofing panel cover board and insulation board composites.In addition, the presently disclosed high-density polymer orpredominantly polymer material cover board does not support mold growth,there are no glass fiber shards to cause skin and eye irritation forinstallers, and the cover board is not negatively impacted by theapplication of solvents, hot asphalt, or adhesives.

The presently disclosed prefabricated roofing panel composites includethe cover board with its high density polymer or predominantly polymermaterial core layer that has a density between 6 lbs/ft³ and 25 lbs/ft³and a low-density insulation board with its low-density polymer orpredominantly polymer material foam core layer that has a density lessthan or equal to about 2 lbs/ft³. The bottom major surface of thehigh-density cover board overlies and is bonded to the top major surfaceof the low-density foam insulation board and, in a preferred embodiment,the high-density cover board includes a waterproofing membrane facerthat overlies and is bonded to the top major surface of the high-densitypolymer or predominantly polymer material core of the cover board. Theroofing panel composite may be secured in a roofing system mechanicallywith screws, nails or other mechanical fasteners and/or adhesively withasphalt or other adhesives.

When making the presently disclosed prefabricated roofing panelcomposites, the low-density polymer or predominantly polymer materialfoam core layer of the low-density foam insulation board may be formedwith the high-density core layer of the high-density cover board beingconcurrently or subsequently formed over and bonded to a top majorsurface of the low-density foam insulation board in the same operation.In an alternate version of the method for making the presently disclosedprefabricated roofing panel composite, preformed low-density foaminsulation boards may be fed into a production line with thehigh-density polymer or predominantly polymer material core layer of thecover board being formed over and bonded to the top major surfaces ofthe preformed low-density foam insulation boards. In the method formaking the presently disclosed prefabricated roofing panel composite, nofacer or a common facer may be used intermediate the high-density corelayer of the cover board and the low-density foam core layer of the foaminsulation board. In addition, a waterproofing membrane facer may beapplied and bonded to the top major surface of the high-density polymeror predominantly polymer material core layer of the cover board.

In an embodiment, the presently disclosed prefabricated roofing systempanel comprises a cover board an insulation board. The cover board cancomprise a high-density predominantly polymer material core layer, thehigh-density core layer of the cover board having a density between 6lbs/ft³ and 25 lbs/ft³, the high-density core layer of the cover boardhaving a length, a width, and a thickness, the high density core layerof the cover board having a top major surface and a bottom major surfacethat are each defined by the length and the width of the high densitycore layer. The insulation board can comprise a low-densitypredominantly polymer material foam core layer, the low-density foamcore layer of the insulation board having a density less than or equalto about 2 lbs/ft³, the low-density foam core layer of the insulationboard having a length, a width, and a thickness, the low-density foamcore layer of the insulation board having a top major surface and abottom major surface that are each defined by the length and the widthof the low-density foam core layer. The bottom major surface of thehigh-density core layer of the cover board and the top major surface ofthe low-density foam core layer of the insulation board can besubstantially coextensive. The cover board and the insulation board canhave a common nonwoven mat facer (e.g., a fiberglass mat) that overliesand is bonded to the bottom major surface of the high-density core layerof the cover board and the top major surface of the low-density foamcore layer of the insulation board to bond the cover board and theinsulation board together.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of a presently disclosedprefabricated roofing panel composite that includes a high-densitypolymer or predominantly polymer material cover board and a low-densitypolymer or predominantly polymer material foam insulation board.

FIG. 2 is a schematic perspective view of a presently disclosedprefabricated roofing panel composite that includes a high-densitypolymer or predominantly polymer material cover board, a low-densitypolymer or predominantly polymer material foam insulation board, and atop facer.

FIG. 3 is a schematic perspective view of a presently disclosedprefabricated roofing panel composite that includes a high-densitypolymer or predominantly polymer material cover board, a low-densitypolymer or predominantly polymer material foam insulation board, and ahigh-density polymer or predominantly polymer material baseboard.

FIG. 4 is a schematic perspective view of presently disclosed aprefabricated roofing panel composite that includes a high-densitypolymer or predominantly polymer material cover board, a low-densitypolymer or predominantly polymer material foam insulation board, ahigh-density polymer or predominantly polymer material baseboard, and atop facer.

FIG. 5 is a schematic side view of a first production line that can beused to make a presently disclosed prefabricated roofing panel compositethat includes a high-density polymer or predominantly polymer materialcover board and a low-density polymer or predominantly polymer materialfoam insulation board.

FIG. 6 is a schematic side view of a second production line that can beused to make a presently disclosed prefabricated roofing panel compositethat includes a high-density polymer or predominantly polymer materialcover board and a low-density polymer or predominantly polymer materialfoam insulation board.

FIG. 7 is a schematic side view of a production line that can be used tomake a presently disclosed prefabricated roofing panel composite thatincludes a high-density polymer or predominantly polymer material coverboard, a low-density polymer or predominantly polymer material foaminsulation board, and a high-density polymer or predominantly polymermaterial baseboard.

FIG. 8 is a schematic side view of a third production line that can beused to make a presently disclosed prefabricated roofing panel compositethat includes a high-density polymer or predominantly polymer materialcover board and a low-density polymer or predominantly polymer materialfoam insulation board.

DETAILED DESCRIPTION

FIG. 1 is a schematic perspective view of a presently disclosed firstprefabricated roofing panel composite 30. The prefabricated roofingpanel composite 30 includes a high-density polymer or predominantlypolymer material cover board 32, and an insulation board 34 that, asshown, are bonded directly together. The prefabricated roofing panelcomposite 30 has a top major surface 36 and a bottom major surface 38that are each defined by the length and the width of the roofing panelcomposite. The prefabricated roofing panel composite 30 typically has awidth of about four feet or greater and a length of about four feet orgreater, preferably, about eight feet or greater and could have lengthsthat are limited only by the ability to store, transport and handle theroofing panel composites prior to installation.

In the prefabricated roofing panel composite 30, the cover board 32 hasa high-density polymer or predominantly polymer material core layer 40.The high-density polymer or predominantly polymer material core layer 40of the cover board 32 in the prefabricated roofing panel composite 30has a density between 6 lbs/ft³ and 25 lbs/ft³ and preferably a densityof at least 8 lbs/ft³. The high-density polymer or predominantly polymermaterial core layer 40 of the cover board 32 in the prefabricatedroofing panel composite has a thickness of about 0.25-0.5 inches. Thedensity and thickness of the high-density polymer or predominantlypolymer material core layer 40 of the cover board 32 are selected toprovide the cover board with the compressive strength to resistdeformation and protect the low-density insulation board 34 that isoverlaid by the cover board from damage, and to provide surfacecharacteristics that promote the bonding of a top facer, e.g., awaterproofing membrane, to the high-density core layer 40 of the coverboard.

The insulation board 34 in the prefabricated roofing panel composite 30includes a low-density polymer or predominantly polymer material foamcore layer 42. The low-density polymer or predominantly polymer materialfoam core layer 42 of the insulation board 34 has a density less than orequal to about 2 lbs/ft³, preferably less than 4 lbs/ft³, and typicallya density between about 1 lbs/ft³ and about 3 lbs/ft³. The low-densitypolymer or predominantly polymer material foam core layer 42 has athickness of about 0.50-3.50 inches. The density and thickness of thelow-density polymer or predominantly polymer material foam core layer 42of the insulation board 34 are selected to provide the prefabricatedroofing panel composite 30 with the desired insulating properties forthe roofing system application.

The high-density polymer or predominantly polymer material core layer ofthe cover board may be made of various high-density polymer orpredominantly polymer materials (e.g., a high-density polyisocyanurate,polyurethane, polystyrene, or phenolic material or a high-densitymaterial made of a blend of these materials; a high-densitypolyisocyanurate, polyurethane, polystyrene, or phenolic foam materialor a high-density foam material made of a blend of these materials; ahigh-density predominantly polyisocyanurate, polyurethane, polystyrene,or phenolic material with inorganic filler(s) or a high-density materialmade of a blend of these materials with filler(s); a high-densitypredominantly polyisocyanurate, polyurethane, polystyrene, or phenolicfoam material with inorganic filler(s) or a high-density foam materialmade of a blend of these materials with filler(s), a high-densitymaterial made of other thermoset matrix polymers; etc.). However, apreferred material for the high-density core layer is a high-densitypolyisocyanurate or predominantly polyisocyanurate material or foammaterial. The predominantly polymer materials of the high-density corelayer may contain various powdered and liquid fillers, fiberreinforcements, fungi growth-inhibiting agents, and fire-retardants toreduce the cost of and/or modify the properties of the high-density corelayer, such as but not limited to the compressive strength, thetoughness, the flexibility, the friability, and the fire resistance ofthe core layer. Examples of fillers that may be used in the high-densitypredominantly polymer material core layer are fillers such as limestone(CaCO₃), fiberglass, recycled polyisocyanurate dust, andextenders/plasticizers.

The low-density polymer or predominantly polymer material foam corelayer 42 of the insulation board 34 may be made of various low-densitypolymer or predominantly polymer foam materials (e.g., a low-densitypolyisocyanurate, polyurethane, polystyrene, or phenolic foam materialor a low-density foam material made of a blend of these materials; alow-density predominantly polyisocyanurate, polyurethane, polystyrene,or phenolic foam material with inorganic filler(s) or a low-density foammaterial made of a blend of these materials with filler(s), alow-density foam material made of other thermoset matrix polymers;etc.). However, a preferred material for the low-density core layer 42is a low-density polyisocyanurate or predominantly polyisocyanurate foammaterial.

When the high-density core layer 40 is made of a predominantly polymermaterial, the high-density predominantly polymer material of the corelayer 40 may contain various powdered and liquid fillers, fiberreinforcements, fire-retardants, fungi growth-inhibiting agents, etc. toreduce the cost and/or modify the properties of the high-density corelayer 40 (such as but not limited to the compressive strength, theflexibility, the friability, the fire resistance of the core layer).When the low-density core layer 42 is made of a predominantly polymermaterial foam, the low-density predominantly polymer material foam corelayer 42 may contain various powdered and liquid fillers fiberreinforcements, fire-retardants, fungi growth-inhibiting agents, etc. toreduce the cost and/or modify the properties of the low-densitypredominantly polymer material foam core layer. Examples of fillers thatmay be used in the high-density core layer 40 of the cover board 32 andthe low-density core layer 42 of the insulation board 34 are fillerssuch as limestone (CaCO₃), fiberglass, recycled polyisocyanurate dust,and extenders/plasticizers.

While, as shown in FIG. 1, the prefabricated roofing panel composite 30has no facers, the prefabricated roofing panel composite 30 could have acommon facer intermediate and bonded to both the bottom major surface ofthe cover board core layer 40 and the top major surface of theinsulation board core layer 42, a top facer bonded to the top majorsurface of the cover board core layer 40, and/or a bottom facer bondedto the bottom major surface of the insulation board core layer 42. Whenused, the common facer of the prefabricated roofing panel composite 30may be any sheet material with good bonding surfaces that facilitates agood bond between the cover board 32 and insulation board 34, such asbut not limited to woven or nonwoven mats made of glass fibers, otherfibers or filaments, scrims, etc. When used, the top facer of theprefabricated roofing panel composite 30 overlies the entire orsubstantially the entire top major surface of the high-density corelayer 40 of the cover board 32. The top facer of the prefabricatedroofing panel composite 30 may be any sheet material that provides asuitable top major surface for the prefabricated roofing panel composite30, such as but not limited to paper, foil, woven or nonwoven mats madeof fiberglass or other fibers or filaments, scrims, etc. When used, thebottom facer of the prefabricated roofing panel composite 30 overliesthe entire or substantially the entire bottom surface of the low-densityfoam core layer 42 of the insulation board 34. The bottom facer of theprefabricated roofing panel composite 30 may be any sheet material thatprovides a suitable bottom major surface for the roofing panel composite30, such as but not limited to paper, foil, woven or nonwoven mats madeof fiberglass or other fibers or filaments, scrims, etc.

FIG. 2 is a schematic perspective view of a presently disclosedprefabricated roofing panel composite 50. The prefabricated roofingpanel composite 50 includes the high-density polymer or predominantlypolymer material cover board 32 and the low-density polymer orpredominantly polymer material foam insulation board 34 that, as shownin FIG. 2, are bonded directly together, and a top facer 52. Other thanthe inclusion of the top facer 52, the prefabricated roofing panelcomposite 50 is the same as the prefabricated roofing panel composite 30of FIG. 1.

The top facer 52 of the prefabricated roofing panel composite 50 isbonded to and overlies the entire or substantially the entire topsurface of the high-density polymer or predominantly polymer materialcore layer of the cover board 32. The top facer 52 of the prefabricatedroofing panel composite 50 may be any sheet material that provides asuitable top major surface for the cover board and facer composite, suchas but not limited to paper, foil, woven or nonwoven mats made offiberglass or other fibers or filaments, scrims, etc. However, apreferred sheet material for the top facer 52 is a sheet material thatserves the dual function of providing a facing during the manufacturingprocess and a waterproofing membrane on the finished product such as butnot limited to a bituminous or modified bituminous membrane, or a singleply membrane (e.g., a EPDM, PVC, or TPO membrane). Where the top facer52 is a waterproofing membrane, the facer may extend beyond thehigh-density core layer of the cover board 32 on one or more of the foursides of the core layer, e.g., beyond a side edge and an end edge of thetop major surface of the core layer to provide overlaps for sealing withthe membranes of adjacent panels.

While, as shown in FIG. 2, the prefabricated roofing panel composite 50only has a top facer 52, the prefabricated roofing panel composite 50could have a common facer intermediate and bonded to both the bottommajor surface of the cover board 32 core layer 40 and the top majorsurface of the insulation board 34 core layer 42, and/or a bottom facerbonded to the bottom major surface of the insulation board 34 core layer42. When used, the common facer of the prefabricated roofing panelcomposite 50 may be any sheet material with good bonding surfaces thatfacilitates a good bond between the cover board 32 and insulation board34, such as but not limited to woven or nonwoven mats made of glassfibers, other fibers or filaments, scrims, etc. When used, the bottomfacer of the prefabricated roofing panel composite 50 overlies theentire or substantially the entire bottom surface of the low-densityfoam core layer of the insulation board 34. The bottom facer of theprefabricated roofing panel composite 50 may be any sheet material thatprovides a suitable bottom major surface for the roofing panel composite50, such as but not limited to paper, foil, woven or nonwoven mats madeof fiberglass or other fibers or filaments, scrims, etc.

FIG. 3 is a schematic perspective view of a presently disclosedprefabricated roofing panel composite 60 that includes: a high-densitypolymer or predominantly polymer material cover board 62, a low-densitypolymer or predominantly polymer material foam insulation board 64, anda high-density polymer or predominantly polymer material baseboard 66.The high-density polymer or predominantly polymer material cover board62 and baseboard 66 may have the same density or different densities. Asshown in FIG. 3, the cover board 62, the insulation board 64, and thebaseboard 66 are bonded directly together. The prefabricated roofingpanel composite 60 has a top major surface 68 and a bottom major surface70 that are each defined by the length and the width of theprefabricated roofing panel composite. The prefabricated roofing panelcomposite 60 typically has a width of about four feet or greater and alength of about four feet or greater, preferably, about eight feet orgreater and could have lengths that are limited only by the ability tostore, transport and handle the roofing panel composites prior toinstallation.

In the prefabricated roofing panel composite 60, the cover board 62 hasa high-density polymer or predominantly polymer material core layer 72and the baseboard 66 has a high-density polymer or predominantly polymermaterial core layer 74. The high-density polymer or predominantlypolymer material core layers 72 and 74 each have a density between 6lbs/ft³ and 25 lbs/ft³ and preferably a density of at least 8 lbs/ft³.The high-density polymer or predominantly polymer material core layer 72of the cover board 62 and the high-density polymer or predominantlypolymer material core layer 74 of the baseboard 66 each have a thicknessof about 0.25-0.5 inches. The density and thickness of the high-densitypolymer or predominantly polymer material core layer 72 of the coverboard 62 are selected to provide the cover board with the compressivestrength to resist deformation and protect the low-density insulationboard 64 that is overlaid by the cover board from damage, and to providesurface characteristics that promote the bonding of a top facer, e.g., awaterproofing membrane, to the core layer 72 of the cover board.

The insulation board 64 in the prefabricated roofing panel composite 60includes a low-density polymer or predominantly polymer foam core layer76. The low-density polymer or predominantly polymer material foam corelayer 76 of the insulation board 64 has a density less than or equal toabout 2 lbs/ft³, preferably less than 4 lbs/ft³, and typically a densitybetween about 1 lbs/ft³ and about 3 lbs/ft³. The low-density polymer orpredominantly polymer material foam core layer 76 has a thickness ofabout 0.50-3.50 inches. The density and thickness of the low-densitypolymer or predominantly polymer material foam core layer 76 of theinsulation board 64 are selected to provide the prefabricated roofingpanel composite 60 with the desired insulating properties for theroofing system application.

The high-density polymer or predominantly polymer material core layers72 and 74 of the cover board 62 and the baseboard 66 may be made ofvarious high-density polymer or predominantly polymer materials (e.g., ahigh-density polyisocyanurate, polyurethane, polystyrene, or phenolicmaterial or a high-density material made of a blend of these materials;a high-density polyisocyanurate, polyurethane, polystyrene, or phenolicfoam material or a high-density foam material made of a blend of thesematerials; a high-density predominantly polyisocyanurate, polyurethane,polystyrene, or phenolic material with inorganic filler(s) or ahigh-density material made of a blend of these materials with filler(s);a high-density predominantly polyisocyanurate, polyurethane,polystyrene, or phenolic foam material with inorganic filler(s) or ahigh-density foam material made of a blend of these materials withfiller(s), a high-density material made of other thermoset matrixpolymers; etc.). However, a preferred material for the high-density corelayers 72 and 74 is a high-density polyisocyanurate or predominantlypolyisocyanurate material or foam material.

The low-density polymer or predominantly polymer material foam corelayer 76 of the insulation board 64 may be made of various low-densitypolymer or predominantly polymer foam materials (e.g., a low-densitypolyisocyanurate, polyurethane, polystyrene, or phenolic foam materialor a low-density foam material made of a blend of these materials; alow-density predominantly polyisocyanurate, polyurethane, polystyrene,or phenolic foam material with inorganic filler(s) or a low-density foammaterial made of a blend of these materials with filler(s), alow-density material made of other thermoset matrix polymers; etc.).However, a preferred material for the low-density core layer 76 is alow-density polyisocyanurate or predominantly polyisocyanurate foammaterial.

When the high-density core layers 72 and 74 are made of a predominantlypolymer material, the high-density predominantly polymer material of thecore layers 72 and 74 may contain various powdered and liquid fillers,fiber reinforcements, fire-retardants, fungi growth-inhibiting agents,etc. to reduce the cost and/or modify the properties of the high-densitycore layers 72 and 74 (such as but not limited to the compressivestrength, the flexibility, the friability, the fire resistance of thecore layer). When the low-density core layer 76 is made of apredominantly polymer material foam, the low-density predominantlypolymer material foam core layer 76 may contain various powdered andliquid fillers fiber reinforcements, fire-retardants, fungigrowth-inhibiting agents, etc. to reduce the cost and/or modify theproperties of the low-density foam core layer. Examples of fillers thatmay be used in the high-density core layers 72 of the cover board 62 andthe baseboard 66 and the low-density core layer 76 of the insulationboard 64 are fillers such as limestone (CaCO₃), fiberglass, recycledpolyisocyanurate dust, and extenders/plasticizers.

While, as shown in FIG. 3, the prefabricated roofing panel composite 60has no facers, the prefabricated roofing panel composite 60 could have acommon facer intermediate and bonded to both the bottom major surface ofthe cover board core layer 72 and the top major surface of theinsulation board core layer 76, a common facer intermediate and bondedto both the bottom major surface of the insulation board core layer 76and the top major surface of the baseboard core layer 74, a top facerbonded to the top major surface of the cover board core layer 72, and/ora bottom facer bonded to the bottom major surface of the baseboard corelayer 74. When used, the common facers of the prefabricated roofingpanel composite 60 may be any sheet material with good bonding surfacesthat facilitates a good bond between the cover board 62, the insulationboard 64, and the baseboard 66, such as but not limited to woven ornonwoven mats made of glass fibers, other fibers or filaments, scrims,etc. When used, the top facer of the prefabricated roofing panelcomposite 60 overlies the entire or substantially the entire top majorsurface of the high-density core layer 72 of the cover board 62. The topfacer of the prefabricated roofing panel composite 60 may be any sheetmaterial that provides a suitable top major surface for theprefabricated roofing panel composite 60, such as but not limited topaper, foil, woven or nonwoven mats made of fiberglass or other fibersor filaments, scrims, etc. When used, the bottom facer of theprefabricated roofing panel composite 60 overlies the entire orsubstantially the entire bottom surface of the high-density core layer74 of the baseboard 66. The bottom facer of the prefabricated roofingpanel composite 60 may be any sheet material that provides a suitablebottom major surface for the roofing panel composite 60, such as but notlimited to paper, foil, woven or nonwoven mats made of fiberglass orother fibers or filaments, scrims, etc.

FIG. 4 is a schematic perspective view of a presently disclosedprefabricated roofing panel composite 80. The prefabricated roofingpanel composite 80 includes the high-density polymer or predominantlypolymer material cover board 62, the low-density polymer orpredominantly polymer material foam insulation board 64, and thehigh-density polymer or predominantly polymer material baseboard 66,that, as shown in FIG. 4, are bonded directly together, and a top facer82. Other than the inclusion of a top facer 82, the prefabricatedroofing panel composite 80 of FIG. 4 is the same as the prefabricatedroofing panel composite 60 of FIG. 3.

The top facer 82 of the prefabricated roofing panel composite 80 isbonded to and overlies the entire or substantially the entire topsurface of the high-density polymer or predominantly polymer materialcore layer of the cover board 62. The top facer 82 of the prefabricatedroofing panel composite 80 may be any sheet material that provides asuitable top major surface for the cover board and facer composite, suchas but not limited to paper, foil, woven or nonwoven mats made offiberglass or other fibers or filaments, scrims, etc. However, apreferred sheet material for the top facer 82 is a sheet material thatserves the dual function of providing a facing during the manufacturingprocess and a waterproofing membrane on the finished product such as butnot limited to a bituminous or modified bituminous membrane, or a singleply membrane (e.g., a EPDM, PVC, or TPO membrane). Where the top facer82 is a waterproofing membrane, the facer may extend beyond thehigh-density polymer or predominantly polymer material core layer of thecover board 62 on one or more of the four sides of the core layer, e.g.,beyond a side edge and an end edge of the top major surface of the corelayer to provide membrane overlaps for sealing with the membranes ofadjacent panels.

While, as shown in FIG. 4, the prefabricated roofing panel composite 80only has a top facer 82, the prefabricated roofing panel composite 80could have a common facer intermediate and bonded to both the bottommajor surface of the cover board core layer and the top major surface ofthe insulation board core layer, a common facer intermediate and-bondedto both the bottom major surface of the insulation board core layer andthe top major surface of the baseboard core layer, and/or a bottom facerbonded to the bottom major surface of the baseboard core layer. Whenused, the common facers of the prefabricated roofing panel composite 80may be any sheet material with good bonding surfaces that facilitates agood bond between the cover board and insulation board and theinsulation board and the baseboard, such as but not limited to woven ornonwoven mats made of glass fibers, other fibers or filaments, scrims,etc. When used, the bottom facer of the prefabricated roofing panelcomposite 80 overlies the entire or substantially the entire bottomsurface of the high-density core layer of the baseboard 66. The bottomfacer of the prefabricated roofing panel composite 80 may be any sheetmaterial that provides a suitable bottom major surface for theprefabricated roofing panel composite 80, such as but not limited topaper, foil, woven or nonwoven mats made of fiberglass or other fibersor filaments, scrims, etc.

FIG. 5 is a schematic side view of a first production line 100 that canbe used to continuously make presently disclosed prefabricated roofingpanel composites in line, such as the prefabricated roofing panelcomposites 30 of FIGS. 1 and 50 of FIG. 2. The prefabricated roofingpanel composites 30 and 50 each include a high-density polymer orpredominantly polymer material cover board 32 and a low-density polymeror predominantly polymer material foam insulation board 34. Theproduction line 100 includes: a first forming station 102 for formingthe low-density polymer or predominantly polymer material foaminsulation board 34 of the prefabricated roofing panel composites 30 and50; a second forming station 104 for forming the high-density polymer orpredominantly polymer material cover board 32 of the prefabricatedroofing panel composites 30 and 50; and a cutting station 106 forcutting the prefabricated roofing panel composites 30 and 50 to length.

The first forming station 102 for forming the low-density foaminsulation board 34 includes a conventional dispenser 108 for dispensinga low-density polymer or predominantly polymer material foam precursor110 (e.g., a low-density polyisocyanurate or predominantlypolyisocyanurate foam precursor) onto a facer, when used, overlying aconveyor 112 of two spaced-apart opposed forming conveyers 112 and 114or directly onto the conveyor 112. As the foam precursor 110 passesbetween the forming conveyors 112 and 114, foams and at least partiallysets, the forming conveyors 112 and 114 cooperate to set the thicknessof the low-density polymer or predominantly polymer material foam corelayer 42 of the low-density polymer or predominantly polymer foaminsulation board 34 formed from the precursor 110. The first formingstation 102 also includes supplies (e.g., rolls) of facer materials 116and 118 that can be fed over and/or beneath the low-density polymer orpredominantly polymer material foam precursor 110 to form a common facerof the prefabricated roofing panel composites 30 and 50 and a bottomfacer of the prefabricated roofing panel composites 30 and 50.

The second forming station 104 of the production line 100 for formingthe high-density polymer or predominantly polymer material cover board32 of the prefabricated roofing panel composites 30 and 50 includes aconventional dispenser 120 for dispensing a high-density polymer orpredominantly polymer material or foam precursor 122 (e.g., ahigh-density polyisocyanurate or predominantly polyisocyanurate foamprecursor) onto the low-density polymer or predominantly polymermaterial foam core layer 42 or, when used, a common facer overlying thelow-density polymer or predominantly polymer material foam core layer42. With the high-density polymer or predominantly polymer materialprecursor 122 overlying the low-density foam core layer 42 or, whenused, the common facer, the high-density polymer or predominantlypolymer material precursor 122 and the low-density foam core layer 42pass between two spaced-apart opposed forming conveyers 112 and 124where the high-density polymer or predominantly polymer material corelayer 38 is formed and bonded directly to the low-density foam corelayer 42 or to the common facer overlying the low-density foam corelayer 42. The spaced-apart opposed forming conveyors 112 and 124cooperate to set the thickness of both the high-density polymer orpredominantly polymer material core layer 40 and the prefabricatedroofing panel composite 30 or 50. The second forming station 104 alsoincludes supplies (e.g., rolls) of a facer material 126 that is fed overthe high-density polymer or predominantly polymer material precursor 122to form the top facer 52 of both the high-density cover board 32 and theprefabricated roofing panel composite 50.

With the high-density core layer 40 and the low-density foam core layer42 of the prefabricated roofing panel composite 30 or 50 bonded togetherin the second forming station 104 to form a continuous length of theprefabricated roofing panel composite 30 or 50, the prefabricatedroofing panel composite 30 or 50 is then cut to length to complete theformation of the prefabricated roofing panel composite 30 or 50. In thecutting station 106 a cutter, such as but not limited to a reciprocatingcutter 128, cuts the prefabricated roofing panel composite 30 or 50coming from the second forming station 104 to length.

While the production line 100, as shown, is capable of applying threefacer materials 116, 118, and 126 to the insulation board 34 and thecover board 32 to form the prefabricated roofing panel composites 30 and50. The application of any one, any two, or all of the facing materials116, 118 and 126 to the insulation board and cover board can be omittedto form the prefabricated roofing panel composite 30 and all but the topfacing material can be omitted to form the prefabricated roofing panelcomposite 50 with the desired number of facers. The facers 116, 118 and126 normally prevent the polymer or predominantly polymer layers fromsticking to the conveyors. However, with a shift in the chemistry of theprecursors 110 and 122 to affect the tackiness of the layers produced sothat they do not stick to the surfaces of the conveyors or by applyingrelease films or coatings to the surfaces of the conveyers that will notallow the layers produced to stick to the surfaces of the conveyors,when desired, any one or all of the facing materials are not needed forand could be eliminated from the manufacturing process.

FIG. 6 is a schematic side view of a second production line 200 that canbe used to continuously make presently disclosed prefabricated roofingpanel composites, such as the prefabricated roofing panel composites 30of FIGS. 1 and 50 of FIG. 2. The prefabricated roofing panel composites30 and 50 each include a high-density polymer or predominantly polymermaterial cover board and a low-density polymer or predominantly polymermaterial foam insulation board. The production line 200 includes: anin-feed conveyor 202 for continuously feeding a series of low-densitypolymer or predominantly polymer material foam insulation boards 34 ofthe prefabricated roofing panel composite into a forming station 204;the forming station 204 for forming the high-density polymer orpredominantly polymer material cover board 32 of the prefabricatedroofing panel composites 30 and 50; and a cutting station 206 forcutting the prefabricated roofing panel composites 30 and 50 to length.

The low-density polymer or predominantly polymer material foaminsulation boards 34 may include a top facer that, when used, forms acommon facer of the prefabricated roofing panel composites 30 and 50 andmay include a bottom facer that, when used, forms a bottom facer of theprefabricated roofing panel composites. Preferably, the low-densitypolymer or predominantly polymer material foam insulation boards 34 arefed into the forming station 204 lengthwise with the ends of successiveinsulation boards 34 in the continuous series of insulation boardsabutting each other.

The forming station 204 of the production line 200 for forming thehigh-density polymer or predominantly polymer material cover board 32 ofthe prefabricated roofing panel composite 30 includes a conventionaldispenser 208 for dispensing the high-density polymer or predominantlypolymer material precursor 210 (e.g., a high-density polyisocyanurate orpredominantly polyisocyanurate precursor) directly onto the low-densityfoam core layers 42 of the insulation boards 34 or, when used the commonfacers overlying the low-density foam core layers of the low-densityfoam insulation boards. With the high-density polymer or predominantlypolymer material precursor 210 directly overlying the low-density foamcore layers 42 of the insulation boards or the common facers 36 carriedby the low-density foam insulation boards 34, the high-density polymeror predominantly polymer material precursor 210 and the low-density foaminsulation boards 34 pass between two spaced-apart opposed formingconveyers 212 and 214 where the high-density polymer or predominantlypolymer material core layers 38 of the cover boards 32 are formed andbonded directly to the low-density foam core layers 42 of the insulationboards 34 or to the common facers overlying the low-density foaminsulation board 34. The spaced-apart opposed forming conveyors 212 and214 cooperate to set the thickness of both the high-density polymer orpredominantly polymer material core layer 40 and the prefabricatedroofing panel composite 30 or 50. The forming station 204 also includessupplies (e.g., rolls) of a facer material 216 that is fed over thehigh-density polymer or predominantly polymer material precursor 210 toform the top facer 52 of both the high-density polymer or predominantlypolymer material cover board 32 and the prefabricated roofing panelcomposite 50.

With the high-density core layer 40 and the low-density foam core layer42 of the prefabricated roofing panel composite 30 or 50 bonded togetherin the forming station 204 to form a continuous length of theprefabricated roofing panel composite 30 or 50, the prefabricatedroofing panel composite 30 or 50 is then cut to length to complete theformation of the prefabricated roofing panel composite 30 or 50. In thecutting station 206 a cutter, such as but not limited to a reciprocatingcutter 218, cuts the prefabricated roofing panel composite 30 comingfrom the forming station 204 to length.

The production line 200, as shown, is capable of making theprefabricated roofing panel composite 30 by feeding preformedlow-density polymer or predominantly polymer material foam insulationboards 34 into the forming station 204 and omitting the application ofthe facer material 216 to the cover board 32 and is capable of makingthe prefabricated roofing panel composite 50 by feeding preformedlow-density polymer or predominantly polymer material foam insulationboards 34 into the forming station 204 and applying of the facermaterial 216 to the cover board 32. The facer 216 normally prevents thehigh-density polymer or predominantly polymer material layer fromsticking to the conveyor 212. However, with a shift in the chemistry ofthe precursor 210 to affect the tackiness of the layer produced so thatthe layer does not stick to the surface of the conveyor 212 or byapplying a release film or coating to the surface of the conveyer 212that will not allow the layer produced to stick to the surface of theconveyor, when desired, the facing materials 216 is not needed for andcould be eliminated from the manufacturing process.

FIG. 7 is a schematic side view of a production line 300 that can beused to continuously make a presently disclosed prefabricated roofingpanel composite, such as the prefabricated roofing panel composites 60of FIGS. 3 and 80 of FIG. 4. These prefabricated roofing panelcomposites each include: a high-density polymer or predominantly polymermaterial cover board 62, a low-density polymer or predominantly polymermaterial foam insulation board 64, and a high-density polymer orpredominantly polymer material baseboard 66. The production line 300includes: a first forming station 302 for forming the high-densitypolymer or predominantly polymer material baseboard 66 of theprefabricated roofing panel composites 60 and 80; a second formingstation 304 for forming the low-density polymer or predominantly polymermaterial foam insulation board 64 of the prefabricated roofing panelcomposites 60 and 80; a third forming station 306 for forming thehigh-density polymer or predominantly polymer material cover board 62 ofthe prefabricated roofing panel composites 60 and 80; and a cuttingstation 308 for cutting the prefabricated roofing panel composites 60and 80 to length.

The first forming station 302 for forming the high-density polymer orpredominantly polymer material baseboard 56 includes a conventionaldispenser 310 for dispensing a high-density polymer or predominantlypolymer material precursor 312 (e.g., a high-density polyisocyanurate orpredominantly polyisocyanurate precursor) onto a facer, when used,overlying a conveyor 314 of two spaced-apart opposed forming conveyers314 and 316 or directly onto the conveyor 314. As the precursor 310passes between the forming conveyors 314 and 316, forms and at leastpartially sets, the forming conveyors 314 and 316 cooperate to set thethickness of the high-density polymer or predominantly polymer materialcore layer 74 of the high-density baseboard 66 formed from the precursor310. The first forming station 302 also includes supplies (e.g., rolls)of facer materials 318 and 320 that may be fed over and/or beneath thehigh-density polymer or predominantly polymer material precursor 310 toform, when used, a common facer of the prefabricated roofing panelcomposites 60 and 80 and a bottom facer of the prefabricated roofingpanel composites 60 and 80.

The second forming station 304 of the production line 300 for formingthe low-density polymer or predominantly polymer material foaminsulation board 64 of the prefabricated roofing panel composites 60 and80 includes a conventional dispenser 322 for dispensing a low-densitypolymer or predominantly polymer material foam precursor 324 (e.g., alow-density polyisocyanurate or predominantly polyisocyanurate foamprecursor) directly onto the high-density core layer 74 or, when used,onto a common facer overlying the high-density core layer 74 of thebaseboard 66. With the low-density polymer or predominantly polymermaterial foam precursor 324 directly overlying high-density core layer74 or the common facer overlying the high-density core layer 74 of thebaseboard 66, the low-density polymer or predominantly polymer materialfoam precursor 324 and the high-density core layer 74 pass between twospaced-apart opposed forming conveyers 314 and 326 where the low-densitypolymer or predominantly polymer material foam core layer 76 of theinsulation board 64 is formed and bonded to the high-density core layer74 or the common facer overlying the high-density core layer 74 of thebaseboard 66. The spaced-apart opposed forming conveyors 314 and 326cooperate to set the thickness of the low-density polymer orpredominantly polymer material foam core layer 76 of the insulationboard 64. The second forming station 304 also includes supplies (e.g.,rolls) of a facer material 328 that can be fed over the low-densitypolymer or predominantly polymer material foam precursor 324 to form acommon facer of the prefabricated roofing panel composites 60 and 80.

The third forming station 306 of the production line 300 for forming thehigh-density polymer or predominantly polymer material cover board 62 ofthe prefabricated roofing panel composites 60 and 80 includes aconventional dispenser 330 for dispensing a high-density polymer orpredominantly polymer material precursor 332 (e.g., a high-densitypolyisocyanurate or predominantly polyisocyanurate precursor) directlyonto the low-density foam core layer 76 or the common facer overlyingthe low-density foam core layer 76 of the insulation board 64. With thehigh-density polymer or predominantly polymer material precursor 332overlying the low-density foam core layer 76 or the common faceroverlying the low-density foam core layer 76, the high-density polymeror predominantly polymer material precursor 332, the low-density foaminsulation board 64, and the high-density baseboard 66 pass between twospaced-apart opposed forming conveyers 314 and 334 where thehigh-density polymer or predominantly polymer material core layer 72 ofthe cover board 62 is formed and bonded to the low-density foam corelayer 76 or the common facer overlying the low-density foam core layer76 of the insulation board 64. The spaced-apart opposed formingconveyors 314 and 334 cooperate to set the thickness of both thehigh-density polymer or predominantly polymer material core layer 72 andthe prefabricated roofing panel composite 60 or 80. The third formingstation 306 also includes supplies (e.g., rolls) of a facer material 336that is fed over the high-density polymer or predominantly polymermaterial precursor 332 to form the top facer 82 of both the high-densitycover board 62 and the prefabricated roofing panel composite 80.

With the high-density polymer or predominantly polymer material coverboard 62, the low-density polymer or predominantly polymer material foaminsulation board 64, and the high-density polymer or predominantlypolymer material baseboard 66 of the prefabricated roofing panelcomposites 60 or 80 bonded together in the third forming station 306 toform a continuous length of the prefabricated roofing panel composite 60or 80, the prefabricated roofing panel composite 60 or 80 is then cut tolength to complete the formation of the prefabricated roofing panelcomposite 60 or 80. In the cutting station 308 a cutter, such as but notlimited to a reciprocating cutter 338, cuts the continuous prefabricatedroofing panel composite 60 or 80 coming from the third forming station306 to length.

While the production line 300, as shown, is capable of applying fourfacer materials 318, 320, 328, and 336 to the baseboard 66; theinsulation board 64 and the cover board 62 to form the prefabricatedroofing panel composites 60 and 80. The application of any one, any two,any three or all of the facing materials 318, 320, 328, and 336 to thebaseboard, the insulation board and the cover board can be omitted toform the prefabricated roofing panel composite 60 and all but the topfacing material can be omitted to form the prefabricated roofing panelcomposite 80 with the desired number of facers. The facers 318, 320,328, and 336 normally prevent the composite layers from sticking to theconveyors. However, with a shift in the chemistry of the precursors312,324, and 332 to affect the tackiness of the layers produced so thatthey do not stick to the surfaces of the conveyors or by applyingrelease films or coatings to the surfaces of the conveyers that will notallow the layers produced to stick to the surfaces of the conveyors,when desired, any one or all of the facing materials are not needed forand could be eliminated from the manufacturing process.

FIG. 8 is a schematic side view of another production line 400 that canbe used to continuously make presently disclosed prefabricated roofingpanel composites in line, such as the prefabricated roofing panelcomposites 30 of FIGS. 1 and 50 of FIG. 2. The prefabricated roofingpanel composites 30 and 50 each include a high-density polymer orpredominantly polymer material cover board 32 and a low-density polymeror predominantly polymer material foam insulation board 34. Theproduction line 400 includes: a forming station 402 for forming thelow-density polymer or predominantly polymer material foam insulationboard 34 and the high-density polymer or predominantly polymer materialcover board 32 of the prefabricated roofing panel composites 30 and 50;and a cutting station 404 for cutting the prefabricated roofing panelcomposites 30 and 50 to length.

The forming station 402 for forming the low-density foam insulationboard 34 and the high-density cover board includes a conventionaldispenser 406 for dispensing a low-density polymer or predominantlypolymer material foam precursor 408 (e.g., a low-densitypolyisocyanurate or predominantly polyisocyanurate foam precursor) ontoa facer, when used, overlying a conveyor 410 of two spaced-apart opposedforming conveyers 410 and 412 or directly onto the conveyor 410. Theforming station 402 also includes a conventional dispenser 414 fordispensing a high-density polymer or predominantly polymer materialprecursor 416 (e.g., a high-density polyisocyanurate or predominantlypolyisocyanurate material precursor) onto the low-density polymer orpredominantly polymer material foam precursor of the core layer 42 or,when used, a common facer overlying the low-density polymer orpredominantly polymer material foam precursor of the core layer 42. Asthe layers of precursor 408 and 416 pass between the forming conveyors410 and 412, the precursors form and at least partially set, the formingconveyors 410 and 412 cooperate to set the thickness of the low-densitypolymer or predominantly polymer material foam core layer 42 ofinsulation board 34 formed from the precursor 408, the thickness of thehigh-density polymer or predominantly polymer material core layer 40 ofcover board 32 formed from the precursor 416, and the thickness of theprefabricated roofing panel composite 30 or 50. The forming station 402also includes supplies (e.g., rolls) of facer materials 418, 420, and422 that can be fed over and/or beneath the low-density polymer orpredominantly polymer material foam precursor 408 to form a common facerof the prefabricated roofing panel composites 30 and 50 and a bottomfacer of the prefabricated roofing panel composites 30 and 50 and thatcan be fed over the high-density polymer or predominantly polymermaterial precursor 416 to form a top facer of the prefabricated roofingpanel composites 30 and 50.

With the high-density core layer 40 and the low-density foam core layer42 of the prefabricated roofing panel composite 30 or 50 bonded togetherto form a continuous length of the prefabricated roofing panel composite30 or 50, the prefabricated roofing panel composite 30 or 50 is then cutto length to complete the formation of the prefabricated roofing panelcomposite 30 or 50. In the cutting station 404 a cutter, such as but notlimited to a reciprocating cutter 424, cuts the prefabricated roofingpanel composite 30 or 50 coming from the forming station 402 to length.

While the production line 400, as shown, is capable of applying threefacer materials 418, 420 and 422 to the insulation board 34 and thecover board 32 to form the prefabricated roofing panel composites 30 and50. The application of any one, any two, or all of the facing materials418, 420, and 422 to the insulation board and cover board can be omittedto form the prefabricated roofing panel composite 30 and all but the topfacing material can be omitted to form the prefabricated roofing panelcomposite 50 with the desired number of facers. The facers 418, 420, and422 normally prevent the layers of the composite from sticking to theconveyors. However, with a shift in the chemistry of the precursors 408and 416 to affect the tackiness of the layers produced so that they donot stick to the surfaces of the conveyors or by applying release filmsor coatings to the surfaces of the conveyers that will not allow thelayers produced to stick to the surfaces of the conveyors, when desired,any one or all of the facing materials are not needed for and could beeliminated from the manufacturing process.

Preferably, the low-density polymer or predominantly polymer materialfoam precursors 110, 324, and 408 are low-density polyisocyanurate orpredominantly polymer foam precursors. Preferably, the high-densitypolymer or predominantly polymer material precursors 122, 210, 312, 332,and 416 are high-density polyisocyanurate or predominantlypolyisocyanurate material precursors. The high-density polymer orpredominantly polymer material precursors 122, 210, 312, 332, and 416can be formulated to produce high-density materials or foams bysignificantly reducing or eliminating the blowing agent(s) from theprecursors 122, 210, 312, 332, and 416. Pentane (HFC), micro-spheres,CO₂ and water (as well as other materials) will act as blowing agentsfor the precursors. The relatively high-density layers produced usingthese types of precursors have improved strength characteristics overthe low-density foams normally produced for insulation products. As theamount of blowing agent is reduced in the precursors 122, 210, 312, 332,and 416, the density and the compressive strength of the high-densitylayers produced increase. These types of high-density core layers aremuch more resistant to deformation than the typical low-density foamcore layers.

While various embodiments have been described, it is to be understoodthat variations and modifications can be resorted to as will be apparentto those skilled in the art. For example, the prefabricated roofingpanel composites could be in an upside down orientation to that shownand described in connection with the Figures. Such variations andmodifications are to be considered within the purview and scope of theclaims appended hereto.

1. A prefabricated roofing system panel comprising: a cover board; thecover board comprising a high-density predominantly polymer materialcore layer; the high-density core layer of the cover board having adensity between 6 lbs/ft³ and 25 lbs/ft³; the high-density core layer ofthe cover board having a length, a width, and a thickness; the highdensity core layer of the cover board having a top major surface and abottom major surface that are each defined by the length and the widthof the high density core layer; an insulation board, the insulationboard comprising a low-density predominantly polymer material foam corelayer; the low-density foam core layer of the insulation board having adensity less than or equal to about 2 lbs/ft³; the low-density foam corelayer of the insulation board having a length, a width, and a thickness;the low-density foam core layer of the insulation board having a topmajor surface and a bottom major surface that are each defined by thelength and the width of the low-density foam core layer; and the bottommajor surface of the high-density core layer of the cover board beingbonded to the top major surface of the low-density foam core layer ofthe insulation board; and the bottom major surface of the high-densitycore layer of the cover board and the top major surface of thelow-density foam core layer of the insulation board being substantiallycoextensive.
 2. The prefabricated roofing system panel according toclaim 1, wherein: the thickness of the high-density core layer of thecover board is about 0.25-0.5 inches; and the thickness of the lowdensity foam core layer of the insulation board is about 0.50-3.50inches.
 3. The prefabricated roofing system panel according to claim 1,wherein: the lengths and widths of the high-density core layer of thecover board and the low-density foam core layer of the insulation boardare each about 4 feet or greater.
 4. The prefabricated roofing systempanel according to claim 1, wherein: the lengths of the high-densitycore layer of the cover board and the low-density foam core layer of theinsulation board are each about 8 feet or greater; and the widths of thehigh-density core layer of the cover board and the low-density foam corelayer of the insulation board are each about 4 feet or greater.
 5. Theprefabricated roofing system panel according to claim 1, wherein: thepolymer material of the high-density core layer of the cover board andthe low-density foam core layer of the insulation board ispolyisocyanurate.
 6. The prefabricated roofing system panel according toclaim 1, wherein: the high-density core layer of the cover board is ahigh-density predominantly polymer material foam core layer.
 7. Theprefabricated roofing system panel according to claim 1, wherein: thecover board includes a top facer that overlies and is bonded to the topmajor surface of the high-density core layer of the cover board; theinsulation board includes a bottom facer that overlies and is bonded tothe bottom major surface of the low-density foam core layer of theinsulation board; and the cover board and the insulation board have acommon facer that overlies and is bonded to the bottom major surface ofthe high-density core layer of the cover board and the top major surfaceof the low-density foam core layer of the insulation board.
 8. Theprefabricated roofing system panel according to claim 7, wherein: thetop facer of the cover board is a waterproofing membrane.
 9. Theprefabricated roofing system panel according to claim 1, including: abaseboard comprising a high-density predominantly polymer material corelayer; the high-density core layer of the baseboard having a densitybetween 6 lbs/ft³ and 25 lbs/ft³; the high-density core layer of thebaseboard having a length, a width, and a thickness; the high-densitycore layer of the baseboard having a top major surface and a bottommajor surface that are defined by the length and the width of thehigh-density core layer of the baseboard; and the bottom major surfaceof the low-density foam core layer of the insulation board being bondedto the top major surface of the high-density core layer of thebaseboard; and the bottom major surface of the low-density foam corelayer of the insulation board and the top major surface of thehigh-density core layer of the baseboard being substantiallycoextensive.
 10. The prefabricated roofing system panel according toclaim 9, wherein: the cover board includes a top facer that overlies andis bonded to the top major surface of the high-density core layer of thecover board; the baseboard includes a bottom facer that overlies and isbonded to the bottom major surface of the high-density core layer of thebaseboard; the cover board and the insulation board have a common facerthat overlies and is bonded to the bottom major surface of thehigh-density core layer of the cover board and the top major surface ofthe low-density foam core layer of the insulation board; and thebaseboard and the insulation board have a common facer that overlies andis bonded to the top major surface of the high-density core layer of thebaseboard and the bottom major surface of the low-density foam corelayer of the insulation board.
 11. The prefabricated roofing systempanel according to claim 10, wherein: the top facer of the cover boardis a waterproofing membrane.
 12. A method of making prefabricatedroofing system panels, comprising: forming an insulation boardcomprising a low-density predominantly polymer material foam core layerhaving a density of less than or equal to about 2 lbs/ft³ in acontinuous process wherein the low-density foam core layer of theinsulation board formed has a width, a thickness, a continuous length,and a top major surface and a bottom major surface that are each definedby the length and the width of the low-density foam core layer of theinsulation board; forming a cover board comprising a high-densitypredominantly polymer material core layer having a density between 6lbs/ft³ and 25 lbs/ft³ in a continuous process wherein the high-densitycore layer of the cover board formed has a width, a thickness, acontinuous length, and a top major surface and a bottom major surfacethat are each defined by the length and the width of the high-densitycore layer of the cover board; and forming the widths of the low-densityfoam core layer of the insulation board and the high-density core layerof the cover board to be substantially the same with the core layer ofone of the boards being formed over and bonded to one of the majorsurfaces of the core layer of the other board to form a composite. 13.The method of making prefabricated roofing system panels according toclaim 12, wherein: the core layers of the insulation board and the coverboard are formed concurrently.
 14. The method of making prefabricatedroofing system panels according to claim 12, wherein: the thickness ofthe high-density core layer of the cover board is about 0.25-0.5 inches;and the thickness of the low density foam core layer of the insulationboard is about 0.50-3.50 inches.
 15. The method of making prefabricatedroofing system panels according to claim 12, wherein: the widths of thehigh-density foam core layer of the cover board and the low-density foamcore layer of the insulation board are each about 4 feet or greater; andthe composite formed by the high-density foam core layer of the coverboard and the low-density foam core layer of the insulation board isperiodically cut to form roofing systems panels that are each about 4feet or greater in length.
 16. The method of making prefabricatedroofing system panels according to claim 12, wherein: the widths of thehigh-density foam core layer of the cover board and the low-density foamcore layer of the insulation board are each about 4 feet or greater; andthe composite formed by the high-density core layer of the cover boardand the low-density foam core layer of the insulation board isperiodically cut to form roofing system panels that are each about 8feet or greater in length.
 17. The method of making prefabricatedroofing system panels according to claim 12, wherein: the polymermaterial of the high-density core layer of the cover board and thelow-density foam core layer of the insulation board is polyisocyanurate.18. The method of making prefabricated roofing system panels accordingto claim 12, wherein: the high-density core layer of the cover board isformed over and bonded to the top major surface of the low-density foamcore layer of the insulation board.
 19. The method of makingprefabricated roofing system panels according to claim 12, including:applying a top facer to the low-density foam core layer of theinsulation board during the formation of the low-density foam core layerof the insulation board that overlies and is bonded to the top majorsurface of the low-density foam core layer of the insulation board andapplying a bottom facer to the low-density foam core layer of theinsulation board during the formation of the low-density foam core layerof the insulation board that overlies and is bonded to the bottom majorsurface of the low-density foam core layer of the insulation board;applying a top facer to the high-density core layer of the cover boardduring the formation of the high-density core layer of the cover boardthat overlies and is bonded to the top major surface of the high-densitycore layer of the cover board; and forming the high-density core layerof the cover board on the top facer of the low-density foam core layerof the insulation board whereby the top facer of the low-density foamcore layer of the insulation board becomes a common facer for thehigh-density foam core layer of the cover board and the low-density foamcore layer of the insulation board.
 20. The method of makingprefabricated roofing system panels according to claim 19, wherein: thetop facer applied to the top major surface of the high-density corelayer of the cover board is a waterproofing membrane.
 21. A method ofmaking prefabricated roofing system panels, comprising: feeding a seriesof insulation boards that each comprise a low-density predominantlypolymer material foam core layer having a density of less than or equalto about 2 lbs/ft³ into a production line in a continuous process; thelow-density foam core layer of each of the insulation boards having awidth, a thickness, a length, and a top major surface and a bottom majorsurface that are each defined by the length and the width of thelow-density foam core layer of the insulation board; forming a coverboard comprising a high-density predominantly polymer material corelayer having a density between 6 lbs/ft³ and 25 lbs/ft³ and a widthsubstantially equal to the widths of the low-density foam core layers ofthe insulation boards; the high-density core layer of the cover boardbeing formed in a continuous process over and bonded to the top majorsurfaces of the low-density foam core layers of the insulation boardsfed into the production line to form a composite; and the compositebeing cut to the lengths of the low-density foam core layers of theinsulation boards fed into the production line.
 22. The method of makingprefabricated roofing system panels according to claim 21, wherein: thethickness of the high-density core layer of the cover board is about0.25-0.5 inches; and the thickness of low-density foam core layer ofeach of the insulation boards is about 0.50-3.50 inches;
 23. The methodof making prefabricated roofing system panels according to claim 21,wherein: the widths of the high-density core layer of the cover boardand the low-density foam core layers of each of the insulation boardsare each about 4 feet or greater; and the composite formed by thehigh-density core layer of the cover board and the low-density foam corelayers of each of the insulation boards is periodically cut to formroofing systems panels that are each about 4 feet or greater in length.24. The method of making prefabricated roofing system panels accordingto claim 21, wherein: the widths of the high-density core layer of thecover board and the low-density foam core layers of each of theinsulation boards are each about 4 feet or greater; and the compositeformed by the high-density core layer of the cover board and thelow-density foam core layers of each of the insulation boards isperiodically cut to form roofing system panels that are each about 8feet or greater in length.
 25. The method of making prefabricatedroofing system panels according to claim 21, wherein: the polymermaterial of the high-density core layer of the cover board and thelow-density foam core layers of each of the insulation boards ispolyisocyanurate.
 26. The method of making prefabricated roofing systempanels according to claim 21, wherein: the low-density foam core layersof each of the insulation boards have top and bottom facers that overlieand are bonded to the top and bottom major surfaces of the low-densityfoam core layers of each of the insulation boards; and a top facer isapplied to the high-density core layer of the cover board during theformation of the high-density core layer of the cover board thatoverlies and is bonded to a top major surface of the high-density corelayer of the cover board and the top facers of the low-density foam corelayers of the insulation boards become a bottom facer for thehigh-density core layer of the cover board.
 27. The method of makingprefabricated roofing system panels according to claim 26, wherein: thetop facer applied to the top major surface of the high-density corelayer of the cover board is a waterproofing membrane.
 28. Aprefabricated roofing system panel comprising: a cover board; the coverboard comprising a high-density predominantly polymer material corelayer; the high-density core layer of the cover board having a densitybetween 6 lbs/ft³ and 25 lbs/ft³; the high-density core layer of thecover board having a length, a width, and a thickness; the high densitycore layer of the cover board having a top major surface and a bottommajor surface that are each defined by the length and the width of thehigh density core layer; an insulation board, the insulation boardcomprising a low-density predominantly polymer material foam core layer;the low-density foam core layer of the insulation board having a densityless than or equal to about 2 lbs/ft³; the low-density foam core layerof the insulation board having a length, a width, and a thickness; thelow-density foam core layer of the insulation board having a top majorsurface and a bottom major surface that are each defined by the lengthand the width of the low-density foam core layer; the bottom majorsurface of the high-density core layer of the cover board and the topmajor surface of the low-density foam core layer of the insulation boardbeing substantially coextensive; and the cover board and the insulationboard have a common nonwoven mat facer that overlies and is bonded tothe bottom major surface of the high-density core layer of the coverboard and the top major surface of the low-density foam core layer ofthe insulation board to bond the cover board and the insulation boardtogether.
 29. The prefabricated roofing system panel according to claim28, wherein: the cover board includes a top facer overlying and bondedto the top major surface of the high-density predominately polymermaterial core layer; and the top facer comprises a nonwoven mat.
 30. Theprefabricated roofing system panel according to claim 29, wherein: thenonwoven mat of the top facer is a nonwoven fiberglass mat.
 31. Theprefabricated roofing system panel according to claim 30, wherein: thetop facer is a waterproof membrane.
 32. The prefabricated roofing systempanel according to claim 31, wherein: the top facer extends beyond aside edge and an end edge of the top major surface of the high-densitypredominately polymer material core layer of the cover board.
 33. Theprefabricated roofing system panel according to claim 28, wherein: thethickness of the high-density core layer of the cover board is about0.25-0.5 inches; and the thickness of the low density foam core layer ofthe insulation board is about 0.50-3.50 inches.
 34. The prefabricatedroofing system panel according to claim 28, wherein: the lengths andwidths of the high-density core layer of the cover board and thelow-density foam core layer of the insulation board are each about 4feet or greater.
 35. The prefabricated roofing system panel according toclaim 28, wherein: the lengths of the high-density core layer of thecover board and the low-density foam core layer of the insulation boardare each about 8 feet or greater; and the widths of the high-densitycore layer of the cover board and the low-density foam core layer of theinsulation board are each about 4 feet or greater.
 36. The prefabricatedroofing system panel according to claim 35, wherein: the polymermaterial of the high-density core layer of the cover board and thelow-density foam core layer of the insulation board is polyisocyanurate.37. The prefabricated roofing system panel according to claim 36,wherein: the high-density core layer of the cover board is ahigh-density predominantly polymer material foam core layer.
 38. Theprefabricated roofing system panel according to claim 28, wherein: thenonwoven mat of the common nonwoven mat facer is a fiberglass mat. 39.The prefabricated roofing system panel according to claim 38, wherein:the insulation board includes a bottom facer that overlies and is bondedto the bottom major surface of the low-density foam core layer of theinsulation board; and the bottom facer comprises a nonwoven mat.
 40. Theprefabricated roofing system panel according to claim 28, including: abaseboard comprising a high-density predominantly polymer material corelayer; the high-density core layer of the baseboard having a densitybetween 6 lbs/ft³ and 25 lbs/ft³; the high-density core layer of thebaseboard having a length, a width, and a thickness; the high-densitycore layer of the baseboard having a top major surface and a bottommajor surface that are defined by the length and the width of thehigh-density core layer of the baseboard; and the bottom major surfaceof the low-density foam core layer of the insulation board is bonded tothe top major surface of the high-density core layer of the baseboard;and the bottom major surface of the low-density foam core layer of theinsulation board and the top major surface of the high-density corelayer of the baseboard are substantially coextensive.
 41. Theprefabricated roofing system panel according to claim 40, wherein: thecover board includes a top facer overlying and bonded to the top majorsurface of the high-density predominately polymer material core layer;the baseboard includes a bottom facer that overlies and is bonded to thebottom major surface of the high-density core layer of the baseboard;and the baseboard and the insulation board have a common facer thatoverlies and is bonded to the top major surface of the high-density corelayer of the baseboard and the bottom major surface of the low-densityfoam core layer of the insulation board.
 42. The prefabricated roofingsystem panel according to claim 41, wherein: the top facer, the bottomfacer, and the common facers each comprise a nonwoven mat.
 43. Theprefabricated roofing system panel according to claim 42, wherein: thetop facer is a waterproof membrane.